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2004 Toyota Prius EV (Electric Vehicle) Button Installation Instructions

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Filed Under (Toyota Manuals) by admin on 31-03-2012

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Time and Difficulty: I found the install to be moderately difficult and pretty time-consuming (about 3 hours) ; others have found it simple and report they have done it in as little as 30 minutes. Your experience will depend on your familiarity with the tools and electronics. I, personally, found insertion of the connection pin into the HV ECU plug to be difficult and almost got the first pin irrevocably stuck in the slot. I spent quite a bit of time with that part alone. I also found threading the wire behind the dash to be fairly tricky. I think the average person, not encountering any problems, could do this job in about 1-1½ hours. Procedure in Brief: 1) Remove bottom cover of steering wheel 2) Locate and unplug flasher plug 3) Open plug and remove 1-3 unused connector pins 4) Reattach steering wheel cover 5) Dismantle part of dash (vents) and remove lower glove box 6) Locate HV ECU (gray plugs) and remove lower plug 7) Solder wire to connector pin and insert into ECU plug (#27) 8) Splice EV button ground wire into ECU plug ground wire (#1) 9) Plug ECU plug back into the ECU 10) Thread wire behind dash to opening near dimmer switch 11) Attach switch to cover and solder wires in place 12) Reassemble the dash 13) Test Procedure in Detail: *Review ALL steps before proceeding and be sure you understand all terms used and you’ve looked at all diagrams and pictures. 1) Remove the bottom cover of the steering wheel by releasing the steering wheel adjustment handle and unscrewing the silver screw in that recess. 2004_prius_evv2.doc Page 4 of 20 Last updated March 13th, 2004 Then, turn the steering wheel 90 degrees right and remove the black screw that becomes visible on the right side of the steering column. Then turn the wheel 180 degrees left (90 degrees from normal position) and remove the black screw on the left side of the steering column. Carefully pull down on the lower portion of the steering column cover until it releases. Mine was a bit stiff/stuck to the upper part and you may need to carefully use a butter knife or screwdriver to start prying them apart. 2004_prius_evv2.doc Page 5 of 20 Last updated March 13th, 2004 2) Locate and unplug the white flasher plug visible just on the left side of the bottom of the steering column. 3) 2 little clips keep a cover locked in place. Pull those apart and remove the cover. Inside you’ll see lines of silver connector pins–some with wires attached, some without. You should remove between 1 and 3 of those pins–2 is probably safe, 3 might be better, since if you plan to install an OEM button at some point, you’ll probably need more pins for that. (You need one pin for the procedure, but it’s handy to have a back-up.) To remove the pins, you can use your paper clip to start the process of sliding them out, and then they just pull right out. 2004_prius_evv2.doc Page 6 of 20 Last updated March 13th, 2004 Stick them to a piece of tape or put them somewhere secure so you can find them later. Snap the cover back into place, and plug the flasher plug back in. 4) Replace the steering wheel cover by reversing the process. Be sure everything’s aligned properly and that there are no gaps. 5) Now you’ll need to dismantle part of the dash to get access to the ECU and other areas. First, open the top and bottom glove box doors. Squeeze the inside sides of the lower glove box together to get the catches past the portion of the dash frame that keeps the door from falling all the way open. Then pull the entire door straight toward you – it will unclip from the hinges at the bottom of the glove box. 2004_prius_evv2.doc Page 7 of 20 Last updated March 13th, 2004 You may also need to unclip the little hydraulic piston that keeps the door from falling open too quickly. Next, grasp the bottom of the silver vent piece next to the glove box. Pull it toward you firmly. It should unclip at the bottom first. Then pull the whole unit straight out

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2004 Chevrolet TrailBlazer Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Repair Manual

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Filed Under (Chevrolet Manuals) by admin on 18-02-2012

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This bulletin is being revised to add model years and provide important repair information. Please discard Corporate Bulletin Number 04-08-49-015 (Section 08 — Body and Accessories). Condition Some customers may comment on a noise coming from the instrument panel cluster (IPC) while driving or on initial start-up. Instrument clusters may contain stepper motor gages that can make noise during the following conditions: Subject: Noise Coming From Instrument Panel Cluster (Replace Instrument Panel Cluster (IPC)) Models: 2003-2005 Buick LeSabre 2003-2007 Buick Rendezvous 2004-2005 Buick Rainier 2003-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003-2005 Chevrolet Cavalier, Impala, Monte Carlo 2003-2006 Chevrolet Avalanche, Suburban, Tahoe, TrailBlazer EXT 2003-2007 Chevrolet Silverado Classic, TrailBlazer 2003-2007 Chevrolet Kodiak Models 2004-2006 Chevrolet SSR 2003-2006 GMC Envoy XL, Yukon, Yukon XL 2004-2005 GMC Envoy XUV 2004-2007 GMC Envoy 2003-2007 GMC Sierra Classic 2003-2004 Oldsmobile Bravada 2003-2005 Pontiac Aztek, Bonneville, Sunfire 2003-2005 HUMMER H2 Attention: Appropriate repair is based on vehicle build date. Use GMVIS to determine the vehicle build date. • Initial startup (gages zero/reset)

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2004-2005 FORD F-150 FRONT BRAKE ROUGHNESS/ SHUDDER WHILE BRAKING REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 10-06-2012

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ISSUE b. If new level (47 fin) rotors are present, Some 2004/2005 F-150 vehicles built before perform one (1) of the following: 11/29/2004 may exhibit front brake roughness and or shudder while braking. (1) If rotors are within minimum thickness specifications, machine the rotors using ACTION the Rotunda on vehicle brake lathe and Service the rack and pinion, rotors, and caliper the Rotunda adapter kit 201-R0093. assemblies as needed, based on vehicle build date Refer to the Workshop Manual, Section and current part levels installed on the vehicle. 206-00 for the correct on-vehicle brake Refer to the following Service Procedure. lathe procedure. SERVICE PROCEDURE (2) If rotors are beyond machinable thickness, the front rotors must be 1. Vehicles built prior to 8/20/2003 require the replaced. replacement of the rack and pinion assembly if it has not been replaced. Refer to Workshop 3. Install new service fix calipers. Manual, Section 206-03 and 211-02. NOTE 2. Determine if the vehicle has the old or new REPLACE CALIPERS WITH NEW SERVICE FIX level rotors (Figure 1). CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY. PART NUMBER PART NAME 6L3Z-2B120-A Caliper Asy (Right Side) 6L3Z-2B121-A Caliper Asy (Left Side) 5L3Z-1102-AB Rotor (4X2, 6 Lug) 5L3Z-1102-BA Rotor (4X2, 7 Lug) 5L3Z-1125-AA Rotor (4X4, 6 Lug) 5L3Z-1125-BA Rotor (4X4, 7 Lug) 6L3Z-3504-AA Steering Gear (Super Cab/Crew 4X2) 6L3Z-3504-BA Steering Gear (Super Cab/Crew 4X4) Figure 1 – Article 05-21-19 6L3Z-3504-CA Steering Gear (Regular Cab 4X2) 6L3Z-3504-DA Steering Gear (Regular Cab 4X4) a. If old level rotors, replace the front rotors 6L3Z-3C294-AA Retainer Spindle Nut and front caliper assemblies. Refer to Workshop Manual, Section 206-00 for front rotor and caliper replacement.

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2004 Chevrolet Silverado 1500 WHEEL HUB, BEARING, AND SEAL REPLACEMENT (4WD) MANUAL

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Filed Under (Chevrolet Manuals) by admin on 27-06-2012

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WHEEL HUB, BEARING, AND SEAL REPLACEMENT (4WD) Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Remove the rotor. Refer to Brake Rotor Replacement – Front in Disc Brakes. Fig. 62: View Of Retaining Bolts For Brake Hose And Wheel Speed Sensor Brackets Courtesy of GENERAL MOTORS CORP. 4. Remove the wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle. 2004 Chevrolet Silverado 1500 2004 SUSPENSION Front Suspension – Sierra & Silverado Fig. 63: Removing The Wheel Drive Shaft Nut Retaining Cover (4WD) Courtesy of GENERAL MOTORS CORP. 5. Remove the wheel drive shaft nut retaining cover. IMPORTANT: Do not reuse the nut. A new nut must be used when installing the wheel drive shaft. Fig. 64: Removing Wheel Driveshaft Assembly Retaining Nut And Washer (4WD) Courtesy of GENERAL MOTORS CORP. 6. Remove the wheel driveshaft assembly retaining nut (2) and washer (3) from the wheel driveshaft. 7. Disengage the wheel drive shaft from the wheel hub and bearing using J 45859 or equivalent Fig. 65: Disengaging The Wheel Drive Shaft From The Wheel Hub And Bearing (4WD) Courtesy of GENERAL MOTORS CORP. 8. Remove the wheel hub and the 15-series bearing mounting bolts

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2004-2007 FORD E-150, E-250, E-250, E-350 4.6L / 5.4L ENGINE-SLOW FUEL FILL REPAIR MANUAL

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Filed Under (Ford Manuals) by admin on 07-06-2012

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ISSUE carbon canister inlet. If there is no free flow Some 2004-2007 E-150 – E-350 vehicles equipped past the CVV, the CVV is failed or frozen with a 4.6L or 5.4L engine and mid-ship fuel tank closed. Replace the CVV. may experience a “Slow to Fill” condition. c. If you have free flow through the CVV and the vent hose, the restriction must be at the ACTION Separator Assembly (Dust Box). Check the Use the Service Procedure to check the canister Canister Separator Assembly for damage, vent tube for a spider web or other obstruction dirt, water or ice contamination and replace before replacing the fuel tank. the Separator Assembly. SERVICE PROCEDURE 2. If the fuel tank is still difficult to fill with the 1. Disconnect the evaporative emission (EVAP) carbon canister disconnected, replace the fuel lines where it connects from the fuel tank to the tank assembly. carbon canister assembly inlet. If the tank can be easily filled, the carbon canister and EVAP PART NUMBER PART NAME lines should be investigated for restriction, 5C2Z-9S327-CA Fuel Vapor Vent continue to Step 1a. If the fuel tank is still 6F1Z-9F945-AA Solenoid Canister Vent difficult to fill with the carbon canister XF2Z-9B328-AA Separator Asy Fuel 6C2Z-9002-AA Tank Asy Fuel disconnected, proceed to Step 2. (Figure 1) F75Z-9F945-CA Solenoid Canister Vent WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071501 Use SLTS Operations If Actual Available; Claim AdditionalTime Diagnosis Or Labor Figure 1 – Article 07-15-1 Performed As Actual Time DEALER CODING a. Spider webs and other debris in the vent CONDITION hose 5C2Z-9S327-CA may restrict the hose. BASIC PART NO. CODE Disconnect and blow out vent hose with 9S327 55 shop air or roll a bearing down the hose to remove the debris.

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2001-2004 FORD Taurus WATER IN THE BLOWER CASE—BLOWER MOTOR SERVICE PROCEDURE

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Filed Under (Ford Manuals) by admin on 14-06-2011

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SERVICE PROCEDURE 1. Access blower motor and resistor per the Workshop Manual Sections 412-02 and 412-04. Inspect for evidence of water/corrosion. If water/corrosion are found or parts have failed, replace per Workshop Manual (blower motor 1F1Z-19805-AA and resistor F6DZ-19A706-AA). 2. Visually inspect the Cowl Vent Screen located under the RH windshield wiper to verify if the Figure 1 – Article 04-15-3 screen is fully seated. Inspect the rubber seal on the vent screen which should be fully seated 5. Locate the tape as shown (Figure 2). Remove against the windshield. If the cowl vent screen the tape and apply Clear Silicone Rubber is not fully seated and appears warped, it must TA-32 to the small hole as shown (Figure 2). be replaced (4F1Z-54018A16-BAA) 3. Remove the cowl vent screen per the vehicle model years and build date information. Workshop Manual Section 412-01 Pollen Filter Removal and inspect the cabin filter to confirm ISSUE it is fully seated. Re-seat the filter as Some vehicles built between 5/1/2001 and necessary. Inspect rain-hat base to make sure 12/15/2003 may exhibit water in the blower case or it is secure and sealed to the body. Reposition on the passenger side floor, an inoperative climate and reseal as necessary using Clear Silicone control blower motor, a motor that operates on high Rubber TA-32. speed only, and/or a blower motor resistor failure. 4. Remove the foam sealant expulsion at lower front outboard corner base of the rain-hat ACTION (Figure 1). Inspect and seal cowl area and install Rain-Hat Extension Seal. Inspect and replace blower motor and/or blower motor resistor if there is evidence of water/corrosion. Refer to the following Service Procedure for details.

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2004-2007 Ford F-Super Duty SLIDING POWER WINDOW (BACK GLASS) SERVICE MANUAL

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Filed Under (Ford Manuals) by admin on 05-07-2012

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FORD: 2004-2007 F-Super Duty ISSUE SERVICE PROCEDURE Some 2004-2007 F-Super Duty vehicles, equipped with a power sliding rear window (back glass), may 1. Prior to window removal, verify that center exhibit a stuck or binding concern. This condition glass is centered in the upper plastic channel may be due to the center glass not being positioned (Figure 1). If center glass is not inside upper correctly inside the upper or lower channel, the plastic channel, pull channel down and out of channel being warped, bent, or center glass upper aluminum channel and slide back in de-bonded. making sure the entire center glass is inside the plastic channel. ACTION Follow the Service Procedure steps to correct the condition. Figure 1 – Article 06-15-5 2. If Step 1 resolves the issue, return the vehicle 4. Refer to window removal procedure. (Refer to back to customer after verifying the window Workshop Manual (WSM), Section 501-11-24 functions properly. If it did not resolve the and 501-11-25.) issue, proceed to Step 3. 5. Remove cable clips from sheet metal. (Refer to 3. Open the rear window approximately half way. WSM, Section 501-11-28.) 6. Remove three (3) motor bracket attaching bolts. (Refer to WSM, Section 501-11-28. 7. Disconnect motor wiring harness from vehicle 9. Pull outer rubber seal from window frame body harness. (Refer to WSM, Section (Figure 2). 501-11-29.) 8. Remove window assembly from vehicle window opening. Figure 2 – Article 06-15-5 10. Locate two (2) screws in bottom of lower frame and remove them with a R1 square bit screw driver (Figure 3). Figure 3 – Article 06-15-5

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2004 – 2006 Toyota Sienna Vehicles Equipped w/ Power Back Door (Power Rear Liftgate) Repair Manual

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Filed Under (Toyota Manuals) by admin on 22-06-2012

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Certain 2004 – 2006 Model Year Sienna vehicles equipped w/Power Back Door (Rear Liftgate) Q1: What is the condition? A1: Toyota has determined that the gas struts used to help lift and support the Power Rear Liftgate in certain 2004 through 2006 model year Sienna vehicles could be wearing out sooner than expected. As the gas struts deteriorate, the performance of the Power Rear Liftgate will begin to degrade, and the Power Rear Liftgate will operate more slowly than when the gas struts were new. Only Sienna vehicles equipped with the Power Rear Liftgate are involved. Q2: Are there any warnings that this condition exists? A2: Owners may notice that the Power Rear Liftgate will not remain in the open position. If not repaired, the gas struts may not be able to support the weight of the liftgate when it is open, and eventually, the gas struts could deteriorate to the point that the liftgate will fall about ten inches after it reaches the fully open position, at which point the power motor will engage and power the liftgate to the fully closed position. This condition may cause injury to a person who is struck by the liftgate when it falls or when it is closing. Q3: When were these vehicles produced, and how many vehicles are involved? A3: Only certain 2004 through 2006 model year Sienna vehicles equipped with the Power Rear Liftgate, produced between January 2003 and December, 2006 are involved. Approximately 196,000 vehicles are involved nationwide.

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Toyota Corolla DVD GPS Navigation Installation Manual

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Filed Under (Toyota Manuals) by admin on 05-12-2011

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onvulsed timbre and enjoy all your journey! Auto-memory function As you must stop the DVD or CD display to switch other interface, auto-memory function will keep the currently information, as your back entertainment system, it can display on top of the stop point automatically. Convulsed timbre and topping enjoy! Four channel outputs, built-in 4 HI-FI amplifiers, presentinga perfect audio and video quality, The sound combining with scene can give you a surprising surround stereoscopic feeling! External car amplifier External car amplifier can be connected to achieve higher request! Entire function control: Entire function control: Entire function control: Entire function control: Through the touch screen, iPodfunctionscan be operated such as play, pause,stop,next, previous, categorize by singer, album, or random playing. Song title display: Song title display: Song title display: Song title display: Contents in the iPod can be displayed like song titles, playing status, time, etc.It is like displaying all the contents of the iPod into the touch screen. The song titles can be in Traditional Chinese, Simplified Chinese,Japanese, English,etc. Timber adjust: Timber adjust: Timber adjust: Timber adjust: As connecting IP od and displaying the song, the timber adjust function can advance the sound effect of I pod. Bluetoothhands-free car kit Bluetoothhands-free car kit Bluetoothhands-free car kit Bluetoothhands-free car kit supportbluetooth hands-free; Auto-distinguish mobile without connection or mobile bracket; you can dial the tele number in the display; the call volume can be adjusted; Auto-storage the incoming telegrams and dial numbers; storage 3partnership mobile Audio EchoClear-Up Audio EchoClear-Up Audio EchoClear-Up Audio EchoClear-Up AEC isonekindof outlying signal voice model, which bases on the pertinence of speaker signal and multipath echo coursed by speaker. We can evaluate the echo by AEC model?and amend the filter parameters continual to make the guesstimate near the true echo. Then takeout the echo guesstimate from the micro input signal to eliminate the echo and realize the perfect hands-free calling

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2004 FORD F150 Door Window Glass-Rear SuperCrew REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 27-06-2012

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REMOVAL AND INSTALLATION 3. Remove the parts in the order indicated in the Door Window Glass — Rear, following illustration and table. SuperCrew To remove individual parts, only carry out the listed steps: NOTE: LH side is shown. RH side is similar. Part Steps 1. Remove the rear door trim panel. For additional Rear door window glass 1-4 information, refer to Section 501-00. Rear door window glass 1-7 regulator 2. Remove the rear door-mounted speaker. For additional information, refer to Section 415-00. Rear door window glass 1, 8 top run ItemPart NumberDescription ItemPart NumberDescription 4 1625712/ Rear door window glass 1 1625766/ Interior moulding (RH/LH) 1625713 (RH/LH) 1625767 Removal Note 2 1627458/ Watershield (RH/LH) 5 180103-14632 Window motor electrical 1627459 Removal Note connector Installation Note 6 W505421-S301Window regulator bolts (5 3 — Rear door window req’d) glass-to-regulator bolt (2 req’d) 7 1627000/ Window regulator assembly Removal Note 1627001 (RH/LH) (Continued) (Continued) Copyright © 2003, Ford Motor Company Last updated: 6/14/2004 2004 F150, 12/2003 501-00-2 501-00-2 Body System — Exterior REMOVAL AND INSTALLATION (Continued) Item 4: Rear Door Window Glass Removal ItemPart NumberDescription Note 8 1625766/ Rear door window glass top 1. Pull the glass out through the top inboard side 1625767 run (RH/LH) Removal Note of the door. 9 1625596/ Exterior moulding (right side) Item 8: Rear Door Window Glass Top Run 1625597 (RH/LH) Removal Note 4. To install, reverse the removal procedure. 1. Remove the glass top run through the top opening of rear door. Item 2: Watershield Removal Note Item 2: Watershield Installation Note 1. Do not tear or damage the watershield during disassembly. 1. Watershield must be installed so that edges have a weatherproof seal. Item 3: Rear Door Window Glass-to-Regulator Bolts Removal Note NOTE: Some vehicles may use rivets to attach the glass to the regulator. 1. If removing only the rear door glass regulator assembly and motor, secure the rear door glass in the full up position with tape.

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